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(11) | EP 0 295 140 B1 |
| (12) | EUROPEAN PATENT SPECIFICATION |
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Fluorescent lamp with a predetermined cri and method for making Leuchtstofflampe mit vorausbestimmtem Farbwiedergabeindex und Verfahren zur Herstellung Lampe fluorescente à index du rendu des couleurs prédéterminé et méthode de fabrication |
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| Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). |
[0001] The present invention relates to lamps and more particularly to lamps including a phosphor layer and a non-phosphor layer.
[0002] Various coatings of non-luminescent particulate materials have been found to be useful when applied as an undercoating for the phosphor layer in mercury vapor discharge lamps, including fluorescent lamps. The phosphor coating is disposed on the inner surface of the lamp glass envelope in receptive proximity to the ultraviolet radiation being generated by the mercury discharge.
Examples of non-luminescent particulate materials which have been used in fluorescent lamps such as, for example, aperture fluorescent reprographic lamps, include titanium dioxide, mixtures of titanium dioxide and up to 15 weight percent aluminum oxide, aluminum, and silver. Titanium dioxide is typically used in commercially available aperture fluorescent reprographic lamps.
[0003] In some instances a layer of a non-luminescent particulate material is used to permit reduction in the phosphor coating weight. See, for example, US-A-4,079,288. US-A-4,074,288 discloses employing a reflector layer comprising vapour-formed spherical alumina particles having an individual particle size range from about 40 to 500 nm (400 to 5000 Angstroms) in diameter in fluorescent lamps to enable reduction in phosphor coating weight with minor lumen loss. The lamp data set forth in the patent, however, shows an appreciable drop in lumen output at 100 hours.
[0004] US-A-4,344,016, a US patent corresponding to GB-A-2,044,524, discloses a low pressure mercury vapour discharge lamp having a SiO2 coating with a thickness of 0.05 to 0.7 mg/cm2. The document expressly provides that the use of thicker coatings causes a reduction in the luminous efficacy due to the occurrence of an absorption of the visible light.
[0005] Other attempts to improve the performance of and/or to reduce the costs associated with the manufacture of mercury vapour discharge lamps have involved the use of more than one phosphor layer. While the inclusion of an additional phosphor layer may achieve the desired maintenance improvement or cost reduction, the use of an additional phosphor coating is typically accompanied by a decrease in Colour Rendering Index (CRI) of the lamp including the additional layer of phosphor.
[0006] Thus, it is known from GB-A-2,044,524 to provide a low pressure mercury vapour discharge lamp comprising a lamp envelope, having a pair of electrodes sealed therein, the lamp envelope containing a fill including an inert gas and mercury, and having a fine particle-size silica layer disposed on an inner surface thereof with a coating of phosphor disposed over the silica layer.
[0007] However, in accordance with a first aspect, the low pressure mercury vapour discharge lamp of the present invention is characterised in that the silica layer contains greater than about 0.7 mg/cm2 of fine particle-size silica, the coating of phosphor being selected to provide a predetermined CRI, and in that the lamp has a CRI substantially equal to the CRI of the phosphor coating.
[0008] In accordance with a further aspect of the present invention there is provided a method for making a low pressure mercury vapour discharge lamp as described above including a phosphor, the lamp having a CRI approximately the same as the CRI of the phosphor, the method comprising applying a coating comprising fine particle-size silica at a coating weight greater than 0.7 milligrams per square centimeter to the inner surface of the lamp envelope to form a silica coated envelope; applying a phosphor coating selected to provide a predetermined CRI over the silica layer; and processing the phosphor coated envelope into a finished lamp.
[0009] In accordance with another aspect of the present invention there is provided a method for making a low pressure mercury vapour discharge lamp including a phosphor, the lamp having a CRI approximately the same as the CRI of the phosphor, the method comprising forming a coating suspension comprising fine particle-size silica, water, a negative charge precursor, a defoaming agent, a surface active agent, an insolubilizing agent, a plasticizer, and two water-soluble binders; applying the coating suspension to the inner surface of a lamp envelope to form a coated envelope; heating the coated envelope to cure the coating and remove the water from the coating, the coating containing greater than about 0.7 mg/cm2 of the fine particle-sized silica; applying a suspension of a phosphor selected to provide a predetermined CRI over the cured silica layer; baking the double coated envelope; and processing the phosphor coated envelope into a finished lamp including the steps of introducing a fill including an inert gas and mercury, and sealing a pair of electrodes in the lamp envelope.
[0010] Some preferred embodiments of the present invention will now be discussed by way of example only and with reference to the accompanying drawings, in which:
[0012] FIGURE 2 graphically represents lumen output as a function of the weight of the silica coating after 100 hours of operation for an F40 lamp in accordance with the present invention which includes a phosphor coating with a weight of about 1.7 grams.
[0013] FIGURE 3 graphically represents lumen output as a function of the triphosphor layer weight after 100 hours of operation for a lamp in accordance with the present invention which includes a fine particle-size silica layer with a weight of about 2 grams.
[0014] The present invention is directed to a low pressure mercury vapour discharge lamp including a phosphor, the lamp having a CRI approximately the same as the CRI of the phosphor, and a method for making such a lamp.
[0015] The low pressure mercury vapour discharge lamp of the present invention includes a lamp envelope having an inner surface. A layer of fine particle-size silica is disposed on at least a portion of the inner surface of the lamp envelope at a coating weight greater than about 0.7 mg/cm2 and a phosphor coating is disposed over the silica layer. The phosphor coating may further be disposed on any portion of the inner surface of the envelope not coated with the fine particle-size silica layer.
[0016] In accordance with a preferred embodiment of the present invention it has been found that the Color Rendering Index (CRI) of fluorescent lamps having at least two phosphor layers, one of the phosphor layers being a less expensive phosphor layer used to permit a reduction in the weight of a more expensive phosphor, can be improved by including a layer comprising fine particle-size silica (also referred to herein as silicon dioxide) in the lamp while eliminating the less expensive phosphor layer. Most preferably the silica layer is interposed between the lamp envelope and the phosphor coating whereby no portion of the silica layer is exposed to or in contact with mercury in the lamp. Silica has an affinity for mercury and therefore will absorb mercury upon exposure thereto or contact therewith. The depletion of mercury in the lamp due to absorption of mercury by the silica layer can result in lamp maintenance loss.
[0017] The use of the fine particle-size silica layer under the phosphor coating advantageously improves the performance of the phosphor in the lamp while causing negligible, if any, reduction in CRI of the desired phosphor. In other words, the CRI of a lamp including a fine particle-size silica layer and a coating of phosphor selected to provide a predetermined CRI is approximately the same as the CRI of a lamp including a coating of the same phosphor without the silica layer. The use of the silica layer further provides a lamp with a desired lumen output and CRI approximately equal to the CRI of the desired phosphor while using less phosphor than would be required to get the same lumen output if the desired phosphor were used alone.
[0018] The present invention is particularly advantageous when used in a fluorescent lamp which includes a triphosphor layer. Fluorescent lamps containing a triphosphor layer often include a layer of a less expensive phosphor, for example, a halophosphate phosphor, interposed between the envelope and the triphosphor layer. The halophosphate layer is used to provide the desired lumen output for the lamp while permitting a reduction in the weight amount of the expensive triphosphor phosphor in the lamps. The inclusion of halophosphate layer does, however, result in a lower CRI for the lamp than if the triphosphor were used alone.
[0019] When a layer of fine particle-size silica is substituted for the halophosphate phosphor in the above-described lamp, the lamp provides the desired lumen output with a reduced triphosphor weight without a reduction in CRI.
[0020] For example, an F40 fluorescent lamp including a single layer of a triphosphor blend (with red phosphor Type No. 2342 obtained from the Chemical and Metallurgical Division of GTE Products Corporation, Towanda, Pennsylvania) requires a phosphor coating weight of about 5 grams (3.75 mg/cm2) to obtain a lamp with a commercially acceptable lumen output. A lamp in accordance with the present invention employing from about 1.7 to about 3.5 mg/cm2 fine particle-size SiO2 provides a comparable lumen output with approximately half as much of the same triphosphor blend.
[0021] The silicon dioxide particles used to form the silica layer, or coating, are high purity silicon dioxide, i.e., the silicon dioxide particles used comprise at least 99.0% by weight SiO2. Preferably, the silicon dioxide particles comprise greater than or equal to 99.8 by weight SiO2. The weight percent silicon dioxide represents the degree of purity of the silicon oxide used.
[0022] The coating weight for the silicon dioxide layer is greater than 0.7 mg/cm2 and less than the weight at which the lumen output of the lamp is reduced due to absorption of the visible light by the silicon dioxide layer. For example, a silicon dioxide layer coating weight of from about 0.7 to about 4 milligrams/square centimeter is acceptable. Preferably, the coating weight of the silicon dioxide reflecting layer is from about 1.7 to about 3.5; and most preferably about 2.2 milligrams/square centimeter.
[0023] As used herein, "fine particle-size silica" or "fine particle-size silicon dioxide" refers to silica or silicon dioxide wherein at least about 80 weight percent of the silicon dioxide particles have a primary particle size from about 5 to about 100 nanometers. Preferably, at least about 80 weight of the silica particles has a primary particle size from about 5 to about 100 nm and at least about 50 weight percent of those particles has a primary particle size from about 17 to about 80 nm. Most preferably, the primary particle size distribution peaks at about 40-50 nm.
[0024] A fluorescent lamp in accordance with the present invention includes an envelope having a pair of electrodes sealed therein; a fill including an inert gas at a low pressure and a small quantity of mercury, a fine particle-size silica coating deposited on at least a portion of the inner surface of the lamp envelope; and a phosphor coating deposited over said silica layer. The phosphor may further be disposed on any uncoated portion of the inner surface of the lamp envelope. The phosphor coating may include more than one phosphor layer.
[0025] The fluorescent lamp of the present invention may optionally include additional non-phosphor coatings for various other purposes.
[0026] Referring to FIGURE 1, there is shown an example of a fluorescent lamp in accordance with the present invention. The fluorescent lamp shown in FIGURE 1 comprises an elongated glass, e.g., soda lime silica glass, envelope 1 of circular cross-section. It has the usual electrodes 2 at each end of the envelope 1 supported on lead-in wires. The sealed envelope, or tube, is filled with an inert gas, such as argon or a mixture of inert gases, such as argon and neon, at a low pressure, for example 266 Pa (2 torr); and a small quantity of mercury is added, at least enough to provide a low vapor pressure of, for example, about six (6) microns during operation.
[0027] The inner surface of the tubular glass envelope is first coated with a fine particle-size silicon dioxide coating 3. A layer 4 of the desired phosphor is coated over the silicon dioxide coating.
[0028] In a preferred embodiment of the present invention the phosphor is a triphosphor blend. A triphosphor blend comprises a first luminescent material having an emission band with a maximum between 430 and 490 nm; a second luminescent material having its emission in the range of 520-565 nm; and a third luminescent material having its emission in the range 590-630 nm. Such blends are white-emitting and typically have color temperatures from about 2700 to about 4500K. The relative amounts of the components in the triphosphor blend is a function of the specific identify of the components used and the color desired. Such determinations are easily made by one of ordinary skill in the art.
[0029] As described above, the present invention permits use of a phosphor coating having a weight less than that required to obtain an approximately equal lumen output in a fluorescent lamp including said phosphor coating and no silica layer with negligible, if any, CRI loss. This permits use of a triphosphor layer having a coating weight less than 3.75 mg/cm2. A preferred coating weight for the triphosphor blend is greater than or equal to 0.35 mg/cm2 and less than 3.75 mg/cm2.
[0030] As used herein, "fluorescent lamp" refers to any discharge device including a phosphor excited to fluorescence by ultra-violet radiation, regardless of configuration.
[0032] While the silicon oxide layer of the present invention can be applied to the envelope by fully coating the lamp surface with an organic base-suspension of the above-described silicon dioxide particles, the use of an organic-base suspension may produce poor texture coatings caused, for example, by flaking away of the coating. Flaking is more frequently experienced when applying thicker coatings, e.g., over 2.5 mg/cm2, from organic-base suspensions.
[0033] Advantageously, such flaking is eliminated when the fine particle-size silica layer is applied to the envelope by fully coating the lamp surface with a water-base suspension of the above-described silicon dioxide particles. In addition to the fine particle-size silica, the water-base coating suspension further includes a negative charge precursor, two water-soluble binders, a defoaming agent, a surface active agent, an insolubilizing agent, and a film-plasticizing agent. The coating suspension is applied to the inner surface of the envelope and the coated envelope is then heated at a temperature and for a period of time sufficient to remove the water from the coating and to cure the coating. The phosphor coating is applied thereover by conventional lamp processing techniques.
[0034] Advantageously, the cured silica layer is insoluble when contacted with an aqueous medium. This feature of the silica coating eliminates the need for a bake-out step prior to applying the phosphor coating suspension to the silica-coated envelope.
[0035] More particularly, the fine particle-size silica coating suspension is prepared by mixing a fine particle-size silica, such as AerosilR OX-50 manufactured by DeGussa, Inc., with a mixture of deionized water, a negative charge precursor, for example, an aqueous base such as ammonium hydroxide,a defoaming agent, a surface active agent, an insolubilizing agent, and a plasticizer to form a slurry. Two water soluble binders are also added to the slurry. Preferably the two water soluble binders are added to the slurry in solution form.
[0036] A preferred pair of water soluble binders for use in the present invention are a first binder comprising hydroxyethylcellulose and a second binder comprising poly(ethylene oxide). When this preferred pair of binders is used, the hydroxyethylcellulose concentration is selected such that the cured film applied to the envelope is not soluble in the phosphor coating suspension applied thereover during the phosphor coating step. Preferably, the concentration of hydroxyethylcellulose in the coating suspension is at least 1 weight percent based on the weight of the silica. Most preferably, the concentration is from about 1 to about 1.2 weight percent based on the weight of the silica. At higher concentrations, the solution can become too viscous requiring additional water to be added, thereby lowering the amount of fine particle-size silica which can be deposited on the inner surface of the lamp envelope.
[0037] The use of a single binder, such as hydroxyethylcellulose, in a water-base coating suspension, does not provide uniform distribution of silica on the inner surface of the lamp envelope. An acceptable film texture is characterized by tightly packed silica particles uniformly distributed on the inner surface of the lamp envelope so as to provide a smooth uninterrupted film.
[0038] Advantageously, the further inclusion of a second water-soluble binder, such as, of poly (ethylene oxide) solution produces an acceptable film texture. The concentration of the second water-soluble binder in the coating suspension is selected to produce a smooth film texture. For example, the inclusion of poly (ethylene oxide) in the suspension in an amount of at least 8.8% based on the weight of the fine particle-size silica produces an acceptable film texture. A coating suspension containing 8.8% poly (ethylene oxide) based on the weight of fine particle-size silica deposits a layer containing about 3.0g fine particle-size silica layer on the inside of a 40T12 fluorescent tube (approximate surface area of about 1335 cm2). Thinner films of silica are obtained by diluting the silica coating suspension with additional amounts of a poly (ethylene oxide) solution with no effect on insolubility as long as 1.0% hydroxyethylcellulose based on the silica weight is present in the coating suspension.
[0039] The weight ratio of the insolubilizing agent to the first binder in the coating suspension is at least 0.5. Preferably, the ratio is in the range of 0.5-1.0. At ratios below 0.5, the coating film does not attain film insolubility, i.e., the resultant film at least partially dissolves in the coating suspension when the phosphor is applied thereover. The insolubilizing agent is a material which effects cross-linking of the binders during a low-temperature (e.g., below 300°C) heating step which renders the silica coating insoluble. An example of a preferred insolubilizing agent is dimethylolurea.
[0040] The plasticizer concentration, based on the weight of the silica, is preferably about 2 to about 3% by weight. Below 2% by weight, pinholing can occur after the application of the phosphor coat; and above 3% by weight, coating defects, particularly mottling, can occur. An example of a preferred plasticizer is glycerine.
[0041] The concentration of the negative charge precursor is preferably greater than or equal to about 0.05 moles per 100 grams (g) fine particle-size silica and most preferably greater than or equal to about 0.05 to about 0.091 moles per 100g of the silica. The introduction of negative ions reduces the thickening properties of the negatively charged fine particle-size silica. In amounts below 0.05 moles per 100g silica, the coating suspension may be too viscous to coat bulbs. In amounts in excess of 0.091 moles per 100g silica, the negative charge precursor provides little additional lowering of the viscosity of the suspension. For example, when an aqueous base such as NH4OH is used as the negative charge precursor in an amount of about 0.05 to about 0.091 moles of NH4OH per 100g silica, the viscosity of the fine particle size-silica coating suspension was lowered from 35-40" viscosity (viscosity without the ammonium hydroxide) to 16-20" viscosity (with ammonium hydroxide) measured by the Sylvania Cup.
[0042] The viscosity number given herein was measured as the number of seconds required to empty a special cup, referred to herein as the Sylvania Cup, filled with the material being measured, and having a one-eighth inch diameter hole at the center of its bottom, through which the material may flow. The cup is made from a nickel crucible having an inside diameter, at its top, of 1.5 inches (3.81 cm). Such a crucible has a flat bottom, which has been rounded out for the present purpose so that the overall inside length from the top of the cup to the bottom is 1 1/2 inches (3.81 cm). The cup holds 33 cc of liquid when filled to the top.
[0043] The defoaming agent and surfactant (also referred to herein as a "surface active agent) can be any such materials conventionally employed in lamp coating technology. Such materials are well known in the art.
[0044] Preferably at least about 0.01% defoaming agent based upon the volume of the coating suspension is used and most preferably from about 0.025% to about 0.04%. The concentration of the surfactant in the coating suspension is preferably at least about 0.001% based upon the volume of suspension and most preferably from about 0.0025% to about 0.004%.
[0045] The concentration of the fine particle-size silica in the coating suspension is preferably no more than about 150 g/l and most preferably from about 40 g/l to about 132 g/l. At concentrations less than 40 g/l an insufficient amount of silica may be deposited in the lamp; and at concentrations above 150 g/l non uniform films may occur.
[0046] The following is exemplary of the making of a lamp in accordance with the present invention and is not to be construed as necessarily limiting thereof.
EXAMPLE
[0047] A coating suspension in accordance with the present invention was prepared from the following components mixed together in the order as listed:
| 150cc | deionized water |
| 12cc | ammonium hydroxide Reagent Grade Assay (28-31%) |
| 0.28cc | defoaming agent (Hercules type 831) |
| 0.028cc | surfactant (BASF type 25R-1 Pluronic) |
| 2.5cc | glycerine |
| 0.45g | dimethylolurea |
| 150g | AerosilR OX-50 (obtained from DeGussa, Inc.) |
| 100cc | hydroxyethylcellulose solution containing 1.7 weight percent of the resin (Natrosol (HEC) grade 250 MBR obtained from Hercules) in water |
| 600cc | poly (ethylene oxide) solution containing 2.2 weight percent of the resin (WSRN 2000 obtained from Union Carbide) in water |
[0048] An insoluble fine particle-size silica layer was applied by causing the above-formulated coating suspension to flow down the inner wall of a tubular fluorescent lamp envelope being held in a vertical position.
[0049] After allowing the bulb to drain for 30 seconds, the coated tubes were placed in an air drying chamber maintained at a temperature of 230°F(110°C) for 30 minutes to remove the water and complete the cross linking reaction between the two water-soluble binders (also referred to herein as resins) and the cross-linking reactant, dimethylolurea.
[0050] The preceding Example formulation allowed about 2.5-3.0 grams of AerosilR OX-50 to be deposited on the inner surface of a standard 40 watt T12 fluorescent lamp envelope of circular cross-section. The dried silica coated bulb was allowed to cool to room temperature, following which the silica layer was overcoated with water-base 3K° Royal White triphosphor suspension by known techniques. The double coated bulb was baked at about 600°C for 2 minutes to remove the organic components of the binders. The coated envelope was then processed into a fluorescent lamp by conventional lamp manufacturing techniques. The present invention advantageously eliminates the need for more than one bakeout step in lamp processing.
[0051] An initial lamp test was conducted to compare the performance of a lamp employing a double phosphor coating with a lamp in accordance with the present invention.
[0052] The initial lamp test results are tabulated in Table 1. Lamp A is a Sylvania Standard 3K° Royal White 40T12 fluorescent lamp. The lamp includes two phosphor layers. The first coat applied to the envelope is a warm white halophosphate phosphor and the second coat is a 3K° triphosphor blend, the composition of which is described below. Lamp B is a 40T12 fluorescent lamp in accordance with the present invention. The first coat is a fine particle-size silica layer which was applied by a method similar to that described in the foregoing Example. The second coat is the standard 3K° triphosphor blend described below. The lamps were otherwise fabricated using conventional lamp processing techniques. The weights of the coatings, or layers, in the lamp are set forth in Table I as well as lamp performance data for 10,000 hours, the x-y color coordinates and the CRI for the lamps.
[0053] The standard 3K° blend formulation used in the initial evaluation contained:
| 65.0% | Y2O3:Eu red phosphor |
| 33.5% | Ce, Tb Magnesium Aluminate green phosphor |
| 1.5% | Ba, Mg Aluminate:Eu blue phosphor |
[0054] The initial evaluation showed (at 100 hours) the 3K° Royal White lamps including the single phosphor layer with the silica layer provided a 5 unit improvement in CRI over the standard 3K° Royal White lamps. After 10,000 hours burning, the 3K° Royal White lamps including the silica layer were 1.5% brighter than the standard lamps due to the 2% superior maintenance characteristics. The color of the lamps, including the silica layers, however, were slightly redder.
[0055] The necessary color corrections were determined. The corrected 3K° blend formulation for lamps including a fine particle-size silica layer is as follows:
| 64.0% | Y2O3:Eu red phosphor |
| 34.0% | Ce, Tb Magnesium Aluminate green phosphor |
| 2.0% | Ba, Mg Aluminate:Eu blue phosphor |
[0056] A triphosphor blend containing one percent less red phosphor, 0.5% more green phosphor, and 0.5% more blue than the standard blend is necessary to obtain the standard 3K° color for a fluorescent lamp including a layer of fine particle-size silica interposed between the lamp envelope and the phosphor layer.
[0057] A second lamp test series was also conducted to compare the results of lamps containing different weights of fine particle-size silica in the silica layer. AerosilR OX-50 was used as the fine particle-size silica in this test series. The weight of the fine particle-size silica layer was varied over a range from 0.98-3.38g in 40T12 fluorescent lamps. The silica layer in each lamp was applied by a method similar to the method of the foregoing Example with the amount of poly (ethylene oxide) being increased to apply the lighter silica coating weights. Each lamp of the test series was second coated with approximately the same amount of the standard 3K° triphosphor blend formulation. The coating weights, brightness, color, and CRI results for this second lamp test series are tabulated in Table 2. A small decrease in brightness occurs as the silica layer weight decreases. A 71% reduction in silica layer weight, from 3.38g to 0.98g, results in a brightness loss of 4.5%. Equivalent brightness to the standard 3K° lamp is achieved at the highest silica layer weight of 3.38g. It should be noted, however, that the CRI of all the silica containing lamps remains essentially the same, approximately 84.0, regardless of the OX-50 weight. The 100 hour lumen data for the lamps described in Table 2 is graphically represented in FIGURE 2.
[0058] A third lamp test series involved a second-coat 3K° triphosphor weight series. The 3K° triphosphor coating weight was varied of a range from 0.91g to 2.37g. (The corrected 3K° triphosphor blend formulation was the 3K° triphosphor used in the third lamp series.) The fine particle-size silica layer of each lamp had a weight approximately 2 grams. AerosilR OX-50 was used as the fine particle-size silica in the lamps of this third lamp test series. The results of this lamp series are tabulated in Table 3. As expected, lower brightness (lower lumens) was obtained at lower triphosphor weights. A 61.6% reduction in triphosphor weight, from 2.37g to 0.91g, results in a 22.7% reduction in brightness. However, high CRI's, around 84.0, were obtained, regardless of the triphosphor weight. The 100 hour lumen data for the lamps described in Table 3 is graphically represented in FIGURE 3.
[0059] The silica coating in these tests clearly show that an 83.0-84.0 CRI 2900°K lamp is obtained using a fine particle-size silica first coat and 3K° triphosphor second coat.
[0060] The silica used in the above-described experiments and tests was AerosilR OX-50 obtained from DeGussa, Inc. AerosilR OX-50 is a fluffy white powder and has a BET surface area of 50 ± 15 m2/g. The average primary particle size of OX-50 is 40 nm. AerosilR OX-50 contains greater than 99.8 percent SiO2, less than 0.08 % Al2O3, less than 0.01% Fe2O3, less than 0.03 TiO2, less than 0.01% HCl, and less than 0.1% sieve residue. (OX-50 has a tamped density of approximately 130 g/l).
[0061] While the foregoing lamp tests illustrate the advantages of the present invention when the fine particle-size silica layer comprises silicon dioxide particles having an average primary particle size of 40 nanometers, it is believed that CRI improvements of comparable magnitude will be obtained with silica layers comprising silicon dioxide particles having an average primary particle size from about 16 nm to about 40 nm.
1. A low pressure mercury vapour discharge lamp comprising a lamp envelope (1), having
a pair of electrodes (2) sealed therein, the lamp envelope containing a fill including
an inert gas and mercury, and having a fine particle-size silica layer (3) disposed
on an inner surface thereof with a coating of phosphor (4) disposed over the silica
layer, characterised in that the silica layer contains greater than about 0.7 mg/cm2 of fine particle-size silica, the coating of phosphor (4) being selected to provide
a predetermined Colour Rendering Index CRI, and in that the lamp has a CRI substantially
equal to the CRI of the phosphor coating.
2. A lamp as claimed in claim 1, wherein said phosphor coating (4) consists substantially
of a triphosphor blend.
3. A lamp as claimed in claim 2, wherein said triphosphor blend comprises about 64 wt
% europium activated yttria, about 34 wt % cerium terbium magnesium aluminate, and
about 2 wt % europium activated barium magnesium aluminate.
4. A lamp as claimed in claim 2 or 3, wherein said phosphor coating (4) contains greater
than or equal to about 0.35 and less than 3.75 mg/cm2 triphosphor blend.
5. A method for making a low pressure mercury vapour discharge lamp as claimed in any
one of claims 1-4, comprising:
applying a coating (3) comprising fine particle-size silica at a coating weight greater than about 0.7 milligrams per square centimeter to the inner surface of the lamp envelope (1) to form a coated envelope;
applying a phosphor coating (4) selected to provide a predetermined CRI over the silica layer; and
processing the phosphor coated envelope into a finished lamp.
6. A method as claimed in claim 5, wherein said coating (3) comprising fine particle-size
silica contains greater than about 0.7 to about 4 mg/cm2 fine particle-size silica.
7. A method for making a low pressure mercury vapour discharge lamp including a phosphor,
said lamp having a CRI approximately the same as the CRI of the phosphor, said method
comprising:
forming a coating suspension comprising fine particle-size silica, water, a negative charge precursor, a defoaming agent, a surface active agent, an insolubilizing agent, a plasticizer, and two water-soluble binders:
applying the coating suspension to the inner surface of the lamp envelope (1) to form a coated envelope;
heating the coated envelope to cure the coating (3) and remove the water from the suspension, the coating containing greater than about 0.7 mg/cm2 of the fine particle-sized silica;
applying a suspension of a phosphor selected to provide a predetermined CRI over the cured silica layer;
baking the double-coated envelope (1,3,4); and
processing the coated envelope into a finished lamp including the steps of introducing a fill including an inert gas and mercury, and sealing a pair of electrodes (2) in the lamp envelope (1).
8. A method as claimed in claim 7, wherein said phosphor consists substantially of a
triphosphor blend.
9. A method as claimed in claim 8, wherein said phosphor is deposited in a layer containing
greater than or equal to about 0.35 and less than about 3.75 mg/cm2 triphosphor blend.
10. A method in accordance with any one of Claims 7-9 wherein the fine particle-size silica
comprises at least about 80 weight percent silica particles having a primary particle
size from about 5 to about 100 nm and at least 50 percent of said silica particles
has a primary particle size from about 17 to 80 nm.
11. A method in accordance with any one of Claims 7-10 wherein said fine particle-size
silica has a primary particle size distribution peaking at about 40-50 nm.
12. A method in accordance with any one of Claims 7-11 wherein said fine particle-size
silica consists essentially of AerosilR OX-50.
13. A method in accordance with any one of Claims 7-12 wherein said two water soluble
binders comprise hydroxyethylcellulose and poly(ethylene oxide).
14. A method in accordance with Claim 13 wherein the concentration of hydroxyethylcellulose
in said coating suspension is at least 1 weight percent based upon the weight of silica
in said coating suspension.
15. A method in accordance with Claim 13 or 14 wherein the concentration of said poly(ethylene
oxide) in said coating suspension is at least 8.8% based upon the weight of silica
in said coating suspension.
16. A method in accordance with any one of Claims 13-15 wherein the weight ratio of the
insolubilizing agent to hydroxyethylcellulose in the coating suspension is at least
0.5; the concentration of said plasticizer, based on the weight of silica, is about
2 to about 3 weight percent; and the concentration of the negative charge precursor
is greater than or equal to about 0.051 moles per 100 grams of silica.
17. A method in accordance with Claim 6 wherein the method includes a single baking step.
1. Niederdruck-Quecksilberdampf-Entladungslampe mit einer Lampenhülle (1) und einem darin
eingesiegelten Elektrodenpaar (2), wobei die Lampenhülle eine ein inertes Gas und
Quecksilber aufweisende Füllung enthält und eine auf einer inneren Oberfläche derselben
angeordnete Schicht (3) aus Siliziumoxid feiner Partikelgröße besitzt, über der wiederum
eine Leuchtstoffschicht (4) abgelagert ist, dadurch gekennzeichnet, daß die Siliziumoxidschicht mehr als etwa 0,7 mg/cm2 Siliziumoxid feiner Partikelgröße enthält, daß die Leuchtstoffschicht (4) derart
ausgewählt ist, daß sie für einen vorbestimmten Farbwiedergabeindex CRI sorgt, und
daß die Lampe einen CRI aufweist, der im wesentlichen dem CRI der Leuchtstoffschicht
gleich ist.
2. Lampe nach Anspruch 1, bei welcher die Leuchtstoffschicht (4) im wesentlichen aus
einer Dreibandenmischung besteht.
3. Lampe nach Anspruch 2, bei welcher die Dreibandenmischung aus etwa 64 Gewichtsprozenten
mit Europium aktiviertem Yttrium, etwa 34 Gewichtsprozenten Ceriumterbiummagnesiumaluminat
und etwa 2 Gewichtsprozenten mit Europium aktiviertem Bariummagnesiumaluminat besteht.
4. Lampe nach Anspruch 2 oder 3, bei welcher die Leuchtstoffschicht (4) gleich oder mehr
als 0,35 und weniger als 3,75 mg/cm2 Dreibandenmischung enthält.
5. Verfahren zur Herstellung einer Niederdruck-Quecksilberdampf-Entladungslampe nach
irgendeinem der Ansprüche 1 bis 4 mit den folgenden Schritten:
Aufbringung einer Schicht (3) aus Siliziumoxid mit feiner Partikelgröße mit einem Schichtgewicht größer als etwa 0,7 mg pro Quadratzentimeter auf die innere Oberfläche der Lampenhülle (1), um eine beschichtete Hülle zu bilden;
Aufbringung einer Leuchtstoffschicht (4) auf die Siliziumoxidschicht, wobei erstere ausgewählt ist, um für einen vorbestimmten CRI zu sorgen, und
Weiterverarbeitung der leuchtstoffbeschichteten Hülle zu einer fertigen Lampe.
6. Verfahren nach Anspruch 5, bei welchem die aus Siliziumoxid feiner Partikelgröße bestehende
Schicht (3) mehr als etwa 0,7 bis etwa 4 mg/cm2 Siliziumoxid feiner Partikelgröße enthält.
7. Verfahren zur Herstellung einer Niederdruck-Quecksilberdampf-Entladungslampe mit einem
Leuchtstoff, wobei dieselbe einen CRI aufweist, der näherungsweise der gleiche ist
wie der CRI des Leuchtstoffs, wobei dieses Verfahren umfaßt:
Bildung einer Beschichtungssuspension aus Siliziumoxid feiner Partikelgröße, Wasser, einem Zwischenstoff negativer Ladung, einem Entschäumungsmittel, einem oberflächenaktiven Wirkstoff, einem unlöslich machenden Wirkstoff, einem Plastifizierungsmittel und zwei wasserlöslichen Bindemitteln:
Bildung einer Beschichtungssuspension aus Siliziumoxid feiner Partikelgröße, Wasser, einem Zwischenstoff negativer Ladung, einem Entschäumungsmittel, einem oberflächenaktiven Wirkstoff, einem unlöslich machenden Wirkstoff, einem Plastifizierungsmittel und zwei wasserlöslichen Bindemitteln:
Aufbringung der Beschichtungssuspension auf die innere Oberfläche der Lampenhülle (1) zur Bildung einer beschichteten Hülle; Aufheizung der beschichteten Hülle, um die Schicht (3) auszuhärten und das Wasser aus der Suspension zu entfernen, wobei die Schicht mehr als etwa 0,7mg/cm2 des Siliziumoxids feiner Partikelgröße enthält;
Aufbringung einer Suspension eines Leuchtstoffs, der zur Bewirkung eines vorbestimmten CIR ausgewählt worden ist, auf die ausgehärtete Siliziumoxidschicht;
Backen der doppelt beschichteten Hülle (1, 3, 4); und
Weiterbehandlung der beschichteten Hülle zu einer fertigen Lampe, einschließlich der Schritte der Einführung einer ein inertes Gas und Quecksilber enthaltenden Füllung und Einsiegelung eines Elektrodenpaars (2) in die Lampenhülle (1).
8. Verfahren nach Anspruch 7, bei welchem der Leuchtstoff im wesentlichen aus einer Dreibandenmischung
besteht.
9. Verfahren nach Anspruch 8, bei welchem der Leuchtstoff in einer Schicht abgelagert
wird, die mehr als oder gleich etwa 0,35 und weniger als etwa 3,75 mg/cm2 Dreibandenmischung enthält.
10. Verfahren nach irgendeinem der Ansprüche 7 bis 9, bei welchem das Siliziumoxid feiner
Partikelgröße zumindest etwa 80 Gewichtsprozent Siliziumoxidpartikel mit einer vorherrschenden
Partikelgröße von etwa 5 bis etwa 100 nm und zumindest 50 Prozent der Siliziumoxidpartikel
eine vorherrschende Partikelgröße von etwa 17 bis 80 nm aufweisen.
11. Verfahren nach irgendeinem der Ansprüche 7 bis 10, bei welchem das Siliziumoxid feiner
Partikelgröße eine vorherrschende Partikelgrößenverteilung aufweist, die ihre Spitze
bei etwa 40 bis 50 nm besitzt.
12. Verfahren nach irgendeinem der Ansprüche 7 bis 11, bei welchem das Siliziumoxid feiner
Partikelgröße im wesentlichen aus AerosilR 0X-50 besteht.
13. Verfahren nach irgendeinem der Ansprüche 7 bis 12, bei welchem die beiden wasserlöslichen
Bindemittel Hydroxyäthylzellulose und Poly(äthylenoxid) umfassen.
14. Verfahren nach Anspruch 13, bei welchem die Konzentration an Hydroxyäthylzellulose
in der Beschichtungssuspension mindestens 1 Gewichtsprozent beträgt, basierend auf
dem Gewicht des Siliziumoxids in der Beschichtungssuspension.
15. Verfahren nach Anspruch 13 oder 14, bei welchem die Konzentration des Poly(äthylenoxids)
in der Beschichtungssuspension zumindest 8,8 % beträgt, basierend auf dem Gewicht
des Siliziumoxids in der Beschichtungssuspension.
16. Verfahren nach irgendeinem der Ansprüche 13 bis 15, bei welchem das Gewichtsverhältnis
des unlöslich machenden Wirkstoffs zur Hydroxyäthylzellulose in der Beschichtungssuspension
zumindest 0,5 beträgt, die Konzentration des Plastifizierungsmittels, basierend auf
dem Gewicht des Siliziumoxids, etwa 2 bis etwa 3 Gewichtsprozente beträgt und die
Konzentration des Zwischenstoffs negativer Ladung größer als oder gleich etwa 0,051
Mol pro 100 Gramm an Siliziumoxid ist.
17. Verfahren nach Anspruch 6, welches einen einzigen Backschritt aufweist.
1. Lampe à décharge à vapeur de mercure sous basse pression comprenant une ampoule (1)
de lampe, dans laquelle sont scellées deux électrodes (2), l'ampoule de la lampe enfermant
un remplissage incluant un gaz inerte et du mercure, et ayant une couche de silice
(3) dont les particules sont de fine taille, disposée sur une paroi intérieure de
celle-ci avec un revêtement de luminophores (4) disposé sur la couche de silice,
caractérisée en ce que la couche de silice contient plus de 0,7 mg/cm2 environ de silice dont les particules sont de fine taille, le revêtement de luminophores (4) étant choisi pour obtenir un indice de rendu des couleurs prédéterminé (CRI), et
en ce que la lampe présente un indice de rendu des couleurs substantiellement égal à celui du revêtement de luminophores.
caractérisée en ce que la couche de silice contient plus de 0,7 mg/cm2 environ de silice dont les particules sont de fine taille, le revêtement de luminophores (4) étant choisi pour obtenir un indice de rendu des couleurs prédéterminé (CRI), et
en ce que la lampe présente un indice de rendu des couleurs substantiellement égal à celui du revêtement de luminophores.
2. Lampe selon la revendication 1, dans laquelle le dit revêtement de luminophores (4)
est constitué substantiellement d'un mélange de trois luminophores.
3. Lampe selon la revendication 2, dans laquelle le dit mélange de trois luminophores
comprend environ 64 % en poids d'yttrium activé à l'europium, environ 34 % en poids
d'aluminate de magnésium terbium cérium, et environ 2 % en poids d'aluminate de magnésium
baryum activé à l'europium.
4. Lampe selon la revendication 2 ou 3, dans laquelle le dit revêtement de luminophores
(4) contient une quantité supérieure ou égale à environ 0,35 mg/cm2 et inférieure à 4,75 mg/cm2 du mélange de trois luminophores.
5. Procédé de fabrication d'une lampe à décharge à mercure sous basse pression conformément
à l'une quelconque des revendications 1 à 4 comprenant les étapes suivantes :
application d'un revêtement (3) comprenant de la silice dont les particules sont de fine taille, avec un poids de revêtement supérieur à environ 0,7 mg/cm2, sur la paroi interne de l'ampoule (1) de la lampe pour former une ampoule revêtue ;
application sur la couche de silice d'un revêtement de luminophores (4) choisi pour obtenir un indice de rendu des couleurs (CRI) prédéterminé ; et
transformation de l'ampoule revêtue de luminophores en une lampe achevée.
6. Procédé selon la revendication 5, dans lequel le dit revêtement (3) comprenant de
la silice dont les particules sont de fine taille comprend entre environ 0,7 et environ
4 mg/cm2 de silice dont les particules sont de fine taille.
7. Procédé de fabrication d'une lampe à décharge à vapeur de mercure sous basse pression
incluant un luminophore, la dite lampe ayant un indice de rendu des couleurs approximativement
identique à celui du luminophore, le dit procédé comprenant les étapes suivantes :
formation d'une suspension de revêtement comprenant de la silice dont les particules sont de fine taille, de l'eau, un précurseur de charge négative, un agent anti-mousse, un agent tensio-actif, un agent insolubilisant, un plastifiant et deux liants solubles dans l'eau ;
application de la suspension de revêtement sur la paroi interne de l'ampoule (1) de la lampe pour former une ampoule revêtue ;
chauffage de l'ampoule revêtue pour traiter le revêtement (3) et ôter l'eau de la suspension, le revêtement contenant plus que 0,7 mg/cm2 environ de silice dont les particules sont de fine taille ;
application d'une suspension d'un luminophore choisi pour obtenir un indice de rendu des couleurs prédéterminé sur la couche de silice traitée ;
cuisson de l'ampoule deux fois revêtue (1, 3, 4) ; et
transformation de l'ampoule revêtue en une lampe achevée, incluant les étapes d'introduction d'un remplissage incluant un gaz inerte et du mercure, et de scellement de deux électrodes (2) dans l'ampoule (1) de la lampe.
8. Procédé selon la revendication 5, selon lequel le dit luminophore est constitué substantiellement
d'un mélange de trois luminophores.
9. Procédé selon la revendication 8, selon lequel le dit luminophore est déposé dans
une couche contenant une quantité supérieure ou égale à environ 0,35 mg/cm2 et inférieure à 4,75 mg/cm2 du mélange de trois luminophores.
10. Procédé selon l'une quelconque des revendications 7 à 9, dans lequel la silice dont
les particules sont de fine taille comprend au moins 80 % en poids de particules de
silice dont la taille des particules primaires est comprise entre environ 5 et environ
100 nm et au moins 50 % des dites particules de silice ont une taille des particules
primaires comprise entre environ 17 et 80 nm.
11. Procédé selon l'une quelconque des revendications 7 à 10, dans lequel la dite silice
dont les particules sont de fine taille a une crête de distribution en taille des
particules primaires de l'ordre de 40 à 50 nm environ.
12. Procédé selon l'une quelconque des revendications 7 à 11, dans lequel la dite silice
dont les particules sont de fine taille comprend essentiellement de l'AerosilR OX-50.
13. Procédé selon l'une quelconque des revendications 7 à 12, dans lequel les dits deux
liants solubles dans l'eau comprennent de l'hydroxyéthylcellulose et du poly(oxyde
d'éthylène).
14. Procédé selon la revendication 13, dans lequel la concentration d'hydroxyéthylcellulose
dans la dite suspension de revêtement est au moins de 1 % en poids par rapport au
poids de silice dans la dite suspension de revêtement.
15. Procédé selon la revendication 13 ou 14, dans lequel la concentration du dit poly(oxyde
d'éthylène) dans la dite suspension de revêtement est au moins de 8,8 % par rapport
au poids de silice dans la dite suspension de revêtement.
16. Procédé selon l'une quelconque des revendications 13 à 15, dans lequel le rapport
des poids de l'agent insolubilisant et de l'hydroxyéthylcellulose dans la suspension
de revêtement est au moins de 0,5 ; et la concentration du dit plastifiant, par rapport
au poids de silice, est comprise entre environ 2 et environ 3 % en poids; et la concentration
du précurseur de charge négative est supérieure ou égale à environ 0,051 mole par
100 grammes de silice.
17. Procédé selon la revendication 6, dans lequel le procédé inclut une unique étape de
cuisson.